Modular pallet

ABSTRACT

A modular pallet comprised of a plurality of elongated runner beams arranged in spaced, parallel relation, interconnected by a plurality of transversely positioned elongated slats. The upper surfaces of the runner beams include a plurality of upper recesses, adapted to receive a respective connector portion of an upper slat. End blocks and an intermediate block depend from the lower surface of each runner beam. The blocks include lower recesses to receive a respective connector portion of a lower slat. Front and rear entry openings exist between parallel runner beams. Side entry openings exist between the blocks of a runner beam. In this manner, the front, rear, and opposing sides of the pallet may be engaged by the forks of a forklift or a pallet jack. Structural reinforcement in the form of diagonal bracing and vertical walls is provided both in the runner beams and in the slats.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The invention relates generally to pallets used to store and transport items in stacked relation thereon. More particularly, the invention pertains to plastic, modular pallets, adapted to be engaged by forklifts and pallet jacks from the front, rear, and both opposing sides.

2. Description of the Prior Art

Conventional pallets have been made from pieces of lumber, including blocks and strips variously assembled through the use of nail or screw fasteners. Such pallets are constructed to include fork openings for engagement by the parallel forks of a forklift or a pallet jack. Typically, the forks of a forklift may be space adjusted by the operator to assume a selected width. Pallet jacks, on the other hand, have fixed forks, arranged in closely spaced relation.

Owing to their construction, some wooden pallets present a mechanical interference for entry of the forks of pallet jacks on two sides of the pallet. Thus, these pallets are considered “four-way” for forklifts and “two-way” for pallet jacks. Movement of such pallets presents problems for pallet jack operators when loading and unloading pallets in space-restricted areas, such as trailers.

One wooden pallet design which is only leased for use, is manufactured by CHEP USA, located at 8517 South Park Circle, Orlando, Fla. This CHEP pallet design provides a “four-way” entry both for forklifts and for pallet jacks. It accomplishes this by using a narrow, median support block, at its front, rear, and side entry points. Nevertheless, the CHEP wooden pallet is heavy and cumbersome to use, when compared to conventional pallets. In addition, since such pallets are only leased, long-term use under such terms is more expensive than to purchase conventional pallets.

Other rectangular pallet designs, manufactured from relatively lightweight corrugated paperboard or plastic, have also been devised. Examples of these pallets are shown in U.S. Des. No. 409, 814, and U.S. Pat. No. 5,941,179, granted to the Applicant, herein. The pallets shown in both of these references rely upon runners oriented in the short, or transverse dimension of the pallet, and slats oriented in the long, or longitudinal dimension of the pallet. These pallets are capable of being configured differently, for example, using a different number of upper slats across the runners, as shown in FIGS. 1, 11, 15 and 18. However, the upper surface of the pallets is not co-planar, as shown in both FIGS. 12 and 16. Additionally, in the configuration of the pallet where reinforcement is included below a runner, reliance is made upon a third component, identified as foot frame 32 (see, FIGS. 16 and 22).

SUMMARY OF THE INVENTION

The plastic modular pallet of the present invention is comprised of a plurality of elongated runner beams arranged in spaced, parallel relation. The longitudinal axis of each runner beam is oriented so that it is parallel to the longitudinal axis of the pallet. Structural reinforcement provided by the combination of diagonal bracing and vertical walls, or solely by vertical walls. This structural reinforcement extends between upper and lower sides of the runners, and is provided throughout the structure of the runners.

The upper side of each runner beam includes first connector means in the form of a plurality of depressed planar recesses. Within the floor of each recess is a connector pin. Raised, load-bearing flats are provided between the recesses, so that alternating recesses and flats extend entirely along each runner beam's upper side.

The lower side of each runner beam is provided with means to space the runner beam from the floor or other supporting surface. For that purpose, end spacer blocks are provided at each end of the runner beam, and an intermediate spacer block is located between the end blocks. The end blocks and the intermediate block have bottom sides, and each bottom side is provided with an elevated recess which is identical in size, configuration, and features to the recesses in the upper side of the runner beam.

The runner beams are interconnected and spanned by a plurality of transversely positioned elongated slats. The thickness of each slat is identical to the depth of the recesses in the runner beams. The width of each slat where it connects or interfaces to each runner beam, is identical to the width of the recesses in the runner beams. The width of each slat elsewhere along its length is slightly greater than at the runner beam connection portion. The length of each slat is sufficient to span the transverse dimension of the plurality of runner beams.

One face of each slat is planar. If a slat is installed with its planar face up, then this face will form part of the load-bearing surface for the pallet. If a slat is installed with its planar face down, then this face will form part of the floor engaging surface for the pallet. The exposed, side edges of each slat are beveled. When a slat is installed with its planar face down, the orientation of the outer bevel is upward and inward with respect to the front or rear of the pallet. Thus, when the forks of a pallet jack or a forklift first encounter the pallet in this region, the bevel acts to deflect or direct the forks slightly upwardly, ensuring a proper fork entry and load pickup.

As with the runner beams, structural reinforcement is included throughout the structure of the slats for additional strength. In one embodiment, this reinforcement is provided by the combination of diagonal bracing with vertical walls. In another embodiment, only vertical walls extending between upper and lower sides of the slats provide the structural reinforcement.

Second connector means are provided at the ends, and at an intermediate location, along the other side of each slat. The second connector means are adapted to mate with a respective first connector means of a runner beam. To accomplish that purpose, one side of each second connector means includes a pair of retainer walls arranged in opposing, spaced relation, and a planar floor with a connector aperture located between the retainer walls. The inner, facing portions of the retainer walls include an angled portion terminated at a shelf, forming a locking barb. The planar floor is generally coextensive with the planar recess of the first connector means. In addition, the connector aperture is aligned with the relative location of the connector pin of the first connector means in the planar recess.

Consequently, when the first connector means of a runner beam and a second connector means of a slat are mated: (1) the planar floor and the planar recess are in flush relation; (2) the connector pin is inserted in the connector aperture; (3) the locking barbs of the retainer walls overlap and embrace opposing side edges of the planar recess; and, (4) the planar face of the slat is co-planar with the adjacent raised flats of the runner beam.

Depending upon the user's requirements for strength and ventilation, anywhere between three to nine upper slats are installed on the upper side of the runner beams. If fewer than nine slats are used on the upper side of the runner beams, recess plugs may be installed in the empty, unused recesses in the runner beams. The plugs have a size and configuration substantially identical to the size and configuration of the second connector ends on the slats. In this manner, through any combination of slats, plugs, and raised flats, a substantially continuous and coplanar surface is provided along the upper side of each runner beam.

In addition, three to five lower slats are installed on the bottom sides of the end spacer blocks and the intermediate spacer block. These slats are installed with their planar faces down to engage the support floor, and their second connector means facing up to engage the runner beams. The second connector means mate with the first connector means in the bottom side of the spacer blocks, thereby forming the remainder of the pallet structure.

Side fork openings are defined by the regions between the end and intermediate blocks of a runner beam. There are no floor engaging slats in these openings. Front and rear fork openings are defined by the regions between parallel runner beams, and between the upper slats and the lower slats. In this manner, the front, rear, and opposing sides of the pallet may be engaged by the forks of a forklift or a pallet jack, providing a “four-way” pallet which is both modular, plastic, lightweight and of sufficient strength and durability for commercial use.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of the modular pallet, showing three runner beams interconnected by seven upper slats and five lower slats;

FIG. 2 is an exploded perspective view of the modular pallet of FIG. 1, showing the upper recesses in the upper surface of the runner beams and the lower recesses in the spacer blocks;

FIG. 3 is a fragmentary, perspective view of the underside of an end portion of a runner beam using diagonal bracing and vertical walls for structural reinforcement;

FIG. 4 is a fragmentary, perspective view as in FIG. 3, but showing a runner beam using only vertical walls for structural reinforcement;

FIG. 5 is a fragmentary, exploded, perspective view of an end portion of a runner beam with a single end block in combination with upper and lower slats;

FIG. 6 is a cross-sectional view taken on the line 6-6 in FIG. 4;

FIG. 7 is a perspective view of a lower slat, showing the three couplers and the beveled side edge portions;

FIG. 8 is a fragmentary, top plan view of the end of the upper slat shown in FIG. 5, showing the vertical wall structural reinforcement, the coupler with the prong receiver and the locking barbs, all in broken line;

FIG. 9 is a fragmentary, top plan view of the end of the lower slat shown in FIG. 5, showing the coupler with the prong receiver and the locking barbs;

FIG. 10 is a fragmentary, side elevational view of the right-hand end of the lower slat, shown in FIG. 7;

FIG. 11 is a cross-sectional view taken on the line 11-11 in FIG. 8;

FIG. 12 is a fragmentary, side elevational view of the end of the upper slat shown in FIG. 5, showing both diagonal wall and vertical wall structural reinforcement;

FIG. 13 is a fragmentary, side elevational view of the end of an upper slat using only vertical walls for structural reinforcement; and,

FIG. 14 is a fragmentary, exploded, perspective view of an end portion of a runner beam with double end blocks in combination with respective upper and lower slats and a beam plug;

FIG. 15 is a cross-sectional view taken on the line 15-15 in FIG. 13;

FIG. 16 is a cross-sectional view taken on the line 16-16 in FIG. 17; and,

FIG. 17 is a fragmentary, perspective view of the front left-hand corner of the pallet shown in FIG. 1.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Turning now to the drawings, and in particular to FIG. 1, the modular pallet 11 of the present invention is comprised of a plurality of elongated runner beams 12 arranged in spaced, parallel relation. The longitudinal axis of each runner beam is oriented parallel to the longitudinal axis of the pallet. Typical pallets are sized 40″×48″, so the length of the runner beams for such a typical pallet would be 48″. However, this dimensional information is provided only for example, and not by way of limitation to the disclosure herein.

Structural reinforcement means are provided throughout the runner beams 12, to resist both compressive and bending forces applied by the load on the pallet structure. These forces are particularly great when the pallet is picked up by a forklift or a pallet jack, and transported onto or off of a transport vehicle. To resist such forces, diagonal bracing 13, longitudinal vertical walls 14, and transverse vertical walls 16 are employed. In FIG. 3, the combined use of all three types of reinforcement is shown. Alternatively, as shown in FIG. 4, a runner beam 12 using only longitudinal and transverse vertical walls is disclosed. Integrally molding the longitudinal walls 14 and the transverse walls 16 to extend between with upper side 17 and the lower side 18 of the runner beam, forms reinforcement structures which are similar in cross-section to an “I-beam”, used in building, highway, and bridge construction. (See, FIG. 6). The use of such structural reinforcement provides runner beams which are lightweight and easy to handle, while providing more than adequate strength and durability for the pallet application.

A plurality of upper, first connector means 19 and a plurality of load-bearing flats 21, extend in alternating fashion across the upper side 17 of each runner beam 12. Each connector means 19 includes a recessed planar floor 22, generally square in plan. Floor 22 could assume an alternative configuration, such as rectangular in plan, although corresponding size adjustments to the adjacent flats 21 may be necessary. It is preferable to employ at least one connector pin 23, centrally located and extending perpendicularly from planar floor 22 Connector pin 23 may include facets or other external features which facilitate registration and locking engagement with a corresponding aperture, to be discussed below. Load-bearing flats 21 are raised in elevation, relative to planar floor 22. Flats 21 are co-planar and define the upper, load-bearing surface of pallet 11.

The lower side 18 of runner beam 12 is provided with spacer means 24 to space each runner beam from a supporting surface, such as a warehouse floor or the floor of the container van of a transport vehicle. Preferably, spacer means 24 includes end spacer blocks 26 at each end of the runner beam 12, and an intermediate spacer block 27 between the end blocks. For additional strength, end spacer blocks 26 are of the double cell, or double block variety, providing roughly twice the load bearing capacity of the single intermediate spacer block 26. However, for less rigorous applications, single cell end spacer blocks 28 may be used, as shown in the alternative runner beam construction of FIG. 5.

The end blocks 26 and 28, and the intermediate block 27, have bottom sides provided with a respective, lower first connector means 29. Upper first connector means 19 and lower first connector means 29 are identical in size, configuration, and physical features. Therefore, no further explanation will be given herein, respecting these aspects of lower first connector means 29. However, as is evident from the drawings, the upper first connection means 19 and the lower first connector means 29, are oriented or facing in opposite directions.

The runner beams 12 are interconnected and spanned by a plurality of upper elongated slats 31 and lower elongated slats 32. Slats 31 and 32 are transversely positioned with respect to beams 12, as is shown most clearly in FIGS. 1 and 2. It should be noted that while slats 31 and 32 are attached to different sides of the runner beams 12, they are otherwise identical in size, shape, and physical features. Put another way, slats 31 and 32 are modular and entirely interchangeable with each other. Therefore, the comments made regarding upper slats apply equally well to lower slats, except as such comments pertain to their location in the pallet construction.

The physical characteristics of the slats are very important both to the modular aspects and to the strength and performance of the pallet 11 of the present invention. For example, the thickness, or vertical height, of each slat is identical to the vertical depth of the recess in the first connection means. The width, or transverse dimension, in the portion of each slat where it connects to a runner beam is identical to the width of the recess in the first connection means. The length of each slat is sufficient to span the transverse dimension of the plurality of runner beams.

One face 33 of each slat is planar. If a slat is installed with its planar face 33 facing up, then this face will form part of the upper, load-bearing surface for the pallet. If a slat is installed with its planar face 33 down, then this face will form part of the floor-engaging surface for the pallet. As with the runner beams, structural reinforcement is included throughout the structure of the upper and lower slats for additional strength. This reinforcement is provided by the combination of diagonal bracing with vertical walls, or solely by vertical walls extending between upper and lower face portions of the slats.

Second connector means 34 are provided both at the ends, and at an intermediate location, along the opposing face 36 of each upper and lower slat. The second connector means 34 are adapted to mate with a respective first upper connector means 19 or first lower connector means 29, of a runner beam. To accomplish that purpose, each second connector means 34 includes a pair of retainer walls 37 arranged in opposing, spaced relation, and planar floor 38 with a connector aperture 39 between the retainer walls 37. The inner, facing portions of the retainer walls 37 include an angled portion 41 terminated at a shelf 42, forming a locking barb 43. The planar floor 38 is generally coextensive with the recessed planar floor 22 of the first connector means 19 or 29. In addition, the connector aperture 39 is aligned with the relative location of the connector pin 23 of in the planar floor 22 of the first connector means.

Consequently, when the first connector means 19 of a runner beam 12 and a second connector means 34 of an upper slat 31 are mated: (1) the planar floor and the planar recess are in flush relation; (2) the connector pin is inserted in the connector aperture; (3) the locking barbs of the retainer walls overlap and embrace opposing side edges of the planar recess; and, (4) the planar face of the upper slat is co-planar with the adjacent raised flats of the runner beam. Similarly, when first connector means 29 of a runner beam 12 and a second connector means 34 of a lower slat 32 are mated, identical structural integration of the slat and the runner occur, except the planar faces 33 of the lower slats are co-planar.

It should be noted that the side edges of each slat are provided with opposing beveled portions 44. For the upper slats 31, the beveled portions 44 face down, and are generally non-functional. However, for the lower slats 32, the orientation of the outer or exposed beveled portions 44 is upward and inward with respect to the front entry opening 46 or the rear entry opening 47 of the pallet 11. (See, FIG. 1). Thus, when the forks of a pallet jack or a forklift first encounter the pallet 11 in this region, the exposed bevel portions 44 act to deflect or direct the forks slightly upwardly, ensuring a proper fork entry into the pallet 11.

Because the pallet 11 is modular in design, it may be configured with various numbers of upper and lower slats, as necessary. For example, depending upon the user's requirements for strength and ventilation, three to nine upper slats may be installed on the upper side 17 of the runner beams 12. If fewer than nine slats are used on the upper side 17 of the runner beams 12, beam plugs 48 may be installed in the empty, unused recesses in the runner beams 12. The beam plugs 48 are sized and configured exactly like the size and configuration of the second connector means 34 on the slats. In this manner, through any combination of slats 31, beam plugs 48, and raised flats 21, a substantially continuous and coplanar surface is provided along the load bearing upper side of the pallet 11.

Three to five lower slats 32 are installed on the bottom sides of the end spacer blocks 26 and the intermediate spacer block 27. These lower slats 32 are installed with their planar faces 33 oriented downwardly to engage the support floor, and their second connector means 34 facing upwardly to engage the lower first connection means 29 on the runner beams 12. The second connector means 34 mate with the lower first connector means 29 in the bottom side of the spacer blocks, thereby forming the remainder of the pallet 11.

Front entry opening 46 and rear entry opening 47 are defined by the regions between the parallel runner beams 12, and between the upper slats 31 and the lower slats 32. Side entry openings 49 and 51, are defined by the regions between the end spacer blocks 26 and the intermediate spacer block 27, of a runner beam 12. There are no floor engaging slats in the side entry openings 49 and 51. In this manner, the front, rear, and opposing sides of the pallet may be engaged by the forks of a forklift or a pallet jack. 

1. A plastic modular pallet comprising: a. a plurality of elongated runner beams arranged in spaced, parallel relation, each of said runner beams having an upper side and a lower side, said upper side being provided with a plurality of first connector means along its longitudinal extent, and said lower side including end blocks at each end of said runner beam and an intermediate block positioned between said end blocks, said end blocks and said intermediate block having bottom sides, each said bottom side provided with a respective first connector means; b. a plurality of upper and lower elongated slats, each of said slats including second connector means, said second connector means being adapted to mate with said first connector means located on said upper side of said runner beams and said bottom sides of said end blocks and said intermediate blocks, said elongated slats being transversely positioned with respect to said runner beams, whereby, side fork openings are defined by regions between said end blocks and said intermediate block of said runner beams, and front and rear fork openings are defined by regions between adjacent said parallel runner beams.
 2. A modular pallet as in claim 1 including structural reinforcement means within said runner beams and said slats.
 3. A modular pallet as in claim 2 in which said structural reinforcement means comprises diagonal braces.
 4. A modular pallet as in claim 2 in which said structural reinforcement means comprises vertical walls.
 5. A modular pallet as in claim 1 including three runner beams and at least three slats.
 6. A modular pallet as in claim 1 including three runner beams and three, five, or seven slats mounted on said upper side of said runner beams and at least three slats mounted on said bottom side of said blocks.
 7. A modular pallet as in claim 1 in which said first connector means comprises a planar recess, and said recess is further provided with a connector pin.
 8. A modular pallet as in claim 1 in which said second connector means includes a pair of retainer walls arranged in opposing, spaced relation, and in which a planar floor and connector aperture are provided between said retainer walls.
 9. A modular pallet comprising: a. a plurality of elongated runner beams arranged in spaced, parallel relation, the arrangement of said runner beams having a transverse dimension, each runner beam having an upper side and a lower side, said upper side including in alternating fashion, a plurality of first connector means and a plurality of load-bearing flats, said first connector means being recessed and said flats being raised, said lower side being provided with spacer means to space each runner beam from a supporting surface, said spacer means having a bottom side and including a plurality of said first connector means on said bottom side; and, b. a plurality of elongated upper slats, each said slat having a thickness which is identical to a depth of said first connector means with respect to a plane of said flats, each said slat having a width which is identical to a width of said first connector means, each said slat ends and having a length between said ends which is sufficient to span said transverse dimension of said arrangement of runner beams, each said slat having one side which is planar and another side which includes second connector means, said second connector means being provided at said ends and at an intermediate location between said ends, said second connector means being adapted to mate with a respective said first connector means of a runner beam, whereby, when said plurality of upper slats are installed on said plurality of runner beams, said connector means of each said upper slat are connected to a respective first connector means in said upper side of said runner beam, and said planar side of the slat is co-planar with said plane of an adjacent said flat forming a load-bearing surface.
 10. A modular pallet as in claim 9 further including a plurality of elongated lower slats, said lower slats being identical in size, configuration, and features with respect to said upper slats, said lower slats having second connector means provided at said ends and at an intermediate location between said ends, said second connector means being adapted to mate with a respective one of said plurality of said first connector means on said bottom side of said spacer means, whereby, when said plurality of lower slats are installed on said spacer means, said planar side of said lower slats form a floor engaging surface for the pallet.
 11. A modular pallet as in claim 10 in which side fork openings are defined by regions between said end blocks and said intermediate block of a front runner beam or a rear runner beam, and in which front and rear fork openings are defined by regions between parallel adjacent runner beams, and between said upper slats and said lower slats.
 12. A modular pallet as in claim 9 in which the modular pallet is rectangular, having a longitudinal dimension and a transverse dimension, and in which the longitudinal axis of each said runner beam is parallel to the longitudinal dimension of the pallet.
 13. A modular pallet as in claim 9 in which said runner beams and said slats include structural reinforcement means.
 14. A modular pallet as in claim 13 in which said structural reinforcement means includes a combination of diagonal bracing and vertical walls.
 15. A modular pallet as in claim 13 in which said structural reinforcement means includes vertical walls.
 16. A modular pallet as in claim 9 in which said first connector means has a planar floor including a connector pin.
 17. A modular pallet as in claim 9 in which said spacer means comprises end spacer blocks at each end of said runner beam, and an intermediate spacer block located between said end blocks.
 18. A modular pallet as in claim 9 in which said second connector means comprises a pair of retainer walls arranged in opposing, spaced relation, and a planar floor with a connector aperture between said retainer walls, said retainer walls having inner, facing portions including a bevel terminated at a shelf, forming a locking barb, said planar floor being generally coextensive with a planar recess of said first connector means, and in which said connector aperture is aligned with said connector pin when said second connector mean is mated with said first connector means.
 19. A modular pallet as in claim 9 including three to nine upper slats installed on said upper side of the runner beams.
 20. A modular pallet as in claim 9 including at least one beam plug, said beam plug having a size, configuration, and features identical to said second connector means on said ends of said upper slats, said plug being adapted for installation in a first connector means of one of said runner beams.
 21. A modular pallet as in claim 10 including three to five lower slats installed on said bottom sides of the end spacer blocks and the intermediate spacer block.
 22. An article of manufacture, comprising: an elongated runner beam, said runner beam having an upper side and a lower side, said upper side including in alternating fashion, a plurality of connector means and a plurality of load-bearing flats, said connector means being recessed and said flats being raised, said lower side being provided with spacer means to space each runner beam from a supporting surface, said spacer means having a bottom side and including a plurality of said first connector means on said bottom side.
 23. An article of manufacture as in claim 22 in which each said connector means has a planar floor including a connector pin, and in which said spacer means comprises end spacer blocks at each end of said runner beam and an intermediate spacer block between said end blocks.
 24. An article of manufacture, comprising: a pallet slat having an elongated dimension between two ends, one side of said slat being planar, and the other side of said slat having connector means at said ends and at a location intermediate said ends, said connector means comprising a pair of retainer walls arranged in opposing, spaced relation, and planar floor with a connector aperture between said retainer walls.
 25. An article of manufacture as in claim 24 in which said retainer walls have inner, facing portions which include a bevel terminated at a shelf, forming a locking barb.
 26. An article of manufacture as in claim 25 including structural reinforcement means in said slat, for resisting compressive and bending forces.
 27. An article of manufacture as in claim 26 in which said structural reinforcement means comprises a combination of diagonal bracing with vertical walls extending from said one side to said other side.
 28. An article of manufacture as in claim 26 in which said structural reinforcement means comprises vertical walls extending from said one side to said other side. 